How tight do I need to torque the brake line banjo bolts?

[MaloStapalo]

Swapping over my YJ hoses today to give me some extra slack, cheers to the user who saved me some money from the SS lines. How tight do i need to get the banjo bolts? I am using new copper washers that are the correct size for the TJ not the YJ ones that came with the hoses

I am also flushing the old brake fluid out since I have no record of that ever being done. How much fluid should I buy to exchange the entire system?

 

[tworley]

Its fairly low. between 20-25 ft/lbs

 

[tworley]

Just looked--23 ft/lbs.

 

[MaloStapalo]

Just looked--23 ft/lbs.

That is pretty low, my torque wrench does 25lbs as its lowest. I will slid up my ratchet and use wrist tight. Should be right around the 20lb area.

 

[Jramos013]

Whats the correct crush washer size? All the stores are closed and will be closed for the next to weeks, so i jeed to order online

 

[Jerry Bransford]

That is pretty low, my torque wrench does 25lbs as its lowest. I will slid up my ratchet and use wrist tight. Should be right around the 20lb area.

Old thread but you should not be using a 1/2" torque wrench for anything with that low of a ft-lbs setting. Use a 3/8" torque wrench which is far more accurate at settings in that range.

 

[BuildBreakRepeat]

Does anyone know how thick the copper washers should be? I have a pack of them.

 

[mrblaine]

Does anyone know how thick the copper washers should be? I have a pack of them.

Ideally, they do not need to be that thick. Unfortunately they cut the recessed sealing rings in the caliper body a bit deeper sometimes so you need the washer thick enough to crush and seal and still leave a gap between the face of the banjo fitting and the area around the hole so that they don't touch and stop compression of the washer.

If there isn't a small gap of some determination there, it will be likely that they will leak.

 

[BuildBreakRepeat]

Ideally, they do not need to be that thick. Unfortunately they cut the recessed sealing rings in the caliper body a bit deeper sometimes so you need the washer thick enough to crush and seal and still leave a gap between the face of the banjo fitting and the area around the hole so that they don't touch and stop compression of the washer.

Thank you, here are the spec of the kit I have. Would it be better to use a specific size, or just try each one and see what works best? (thinnest possible without bottoming out mating surface)

 

[mrblaine]

Thank you, here are the spec of the kit I have. Would it be better to use a specific size, or just try each one and see what works best? (thinnest possible without bottoming out mating surface)

View attachment 164247

Thicker always works. The only reason not to make thicker ones is expense.

 

[jjvw]

The Dorman pack of copper washers from the auto parts store has a pair that is thick enough for the YJ hoses.

 

[BuildBreakRepeat]

The Dorman pack of copper washers from the auto parts store has a pair that is thick enough for the YJ hoses.

That’s what I got! The thick pair fits perfect. I’m having some trouble getting the hard line nut off to on the top of the flexible hose connection - any tips?

 

[Rescue6]

I may have missed it but did you get a volume question to get a full flush

 

[mrblaine]

I may have missed it but did you get a volume question to get a full flush

2 pints at the most.

 

[jjvw]

That’s what I got! The thick pair fits perfect. I’m having some trouble getting the hard line nut off to on the top of the flexible hose connection - any tips?

Not from me. Mine haven't gotten stuck.

 

[Rescue6]

2 pints at the most.

Thank you

 

[mrblaine]

Thank you

Pull the old fluid out of the reservoir so you don't have to pump so much dirty fluid through the system.

 

[BuildBreakRepeat]

Not from me. Mine haven't gotten stuck.

For anyone wondering - line wrenches (recommendation by Blaine) made quick work of the tube nut.

 

[toximus]

The Dorman pack of copper washers from the auto parts store has a pair that is thick enough for the YJ hoses.

Dorman 66250 for those shopping at home.

 

[BuildBreakRepeat]

The Dorman pack of copper washers from the auto parts store has a pair that is thick enough for the YJ hoses.

Dorman 66250 for those shopping at home.

Also Dorman 66272 - it’s just the thick pair instead of the variety pack. 25/64”x5/8”x1/16” which is the one you want!